Flush valve structure for a toilet tank

Abstract

A toilet tank flush valve structure includes a valve base. A float assembly that is adjustable in buoyancy is movable between a sealing position and a flushing position. An overflow tube is attached to the float assembly and extends from a lower end in communication with a water outflow passage of the valve base to an upper end in communication with the interior space of the toilet tank. The upper end of the overflow tube is adjustable relative to the float assembly independently of the buoyancy of the float assembly. A guide member guides movement of the float assembly. A stop member on the guide member limits upward travel of the float assembly from its sealing position. The stop member is adjustable in position lengthwise of the guide member or by extension of the guide member independently of the buoyancy of the float assembly.

The invention claimed is: 
     
       1. A toilet tank flush valve structure, for use with a toilet tank that is provided with a water supply valve and has an interior space bounded by a floor formed with an outlet hole, the flush valve structure comprising:
 a valve base for installation in the outlet hole formed in the floor of the toilet tank, the valve base defining a water outflow passageway having an upper end and a lower end and including a first valve member at the upper end of the water outflow passage, 
 a float assembly that is movable relative to the valve base between a sealing position in which a second valve member at a lower end of the float assembly engages the first valve member in sealing relationship and a flushing position in which the second valve member is spaced upwardly from the first valve member, the float assembly having an adjustable buoyancy configured to overcome the head pressure of water above it and float upwards once a flush has been initiated and defining a passageway extending upwardly therethrough, wherein the float assembly comprises:
 an outer shell that:
 is open downwards to define an opening, 
 includes an upper annular wall opposite the opening, and 
 has a lower edge at which the shell is provided with said second valve member, 
 
 a closure member within the outer shell and cooperating with the outer shell to define a float chamber, and 
 an adjustment mechanism disposed within the outer shell and configured to selectively adjust the position of the closure member relative to the upper annular wall to selectively adjust the volume of the float chamber, 
 
 an overflow tube extending upward through the passageway defined by the float assembly, wherein the overflow tube extends upward from a lower end in fluid communication with the water outflow passageway of the valve base to an upper end in fluid communication with the interior space of the toilet tank and is adjustable in position relative to the float assembly independently of adjustment of the closure member relative to the outer shell, and 
 a guide member that extends upward from the valve base through the overflow tube for guiding movement of the float assembly relative to the valve base, and wherein the guide member includes a stop element at a location above the float assembly for limiting upward travel of the float assembly from its sealing position, and the stop element is adjustably positioned relative to the valve base whereby a distance of said upward travel is selectively adjustable, and wherein the guide member defines a fluid passageway delivering water originating from the water supply valve to the valve base; 
 wherein the guide member comprises:
 a lower tubular core segment with outwardly projecting ribs; and 
 an upper tubular core segment engaged with the lower tubular core segment and extends upwards. 
 
 
     
     
       2. A flush valve structure according to  claim 1 , wherein the upper annular wall comprises a downward extension tube and the overflow tube extends within said downward extension tube. 
     
     
       3. A flush valve structure according to  claim 2 , wherein the extension tube has an upper portion of internal diameter slightly greater than the external diameter of the overflow tube, to provide a snug sliding fit of the overflow tube within said upper portion of the extension tube, and a lower portion of reduced internal diameter relative to the upper portion for cooperating with the guide member for guiding movement of the float assembly. 
     
     
       4. A flush valve structure according to  claim 1 , wherein the valve base includes a flange for positioning within the tank above the floor of the toilet tank, a water outflow tube that extends downward from the flange to enter the outlet hole formed in the floor of the toilet tank, and an extension that flares upwardly from the flange, and the first valve member is attached at an upper end of the extension in a position where it may be replaced without removing the valve base from the toilet tank. 
     
     
       5. A flush valve structure according to  claim 1 , wherein the valve base has an internally threaded hole at one side of the water outflow passageway and the lower tubular core segment with outwardly projecting ribs of the guide member is externally threaded at its lower end and is in threaded engagement with the valve base. 
     
     
       6. A flush valve structure according to  claim 1 , wherein:
 the lower tubular core segment is internally threaded proximate the upper end of the overflow tube 
 the upper tubular core segment is externally threaded and releasably engaged with the internal threads of the lower tubular core segment, and 
 the stop element is threadingly attached to the externally threaded upper tubular core segment; 
 wherein adjusting the threaded engagement of the upper tubular core segment within the lower tubular core segment thereby adjusts the vertical position of the stop element. 
 
     
     
       7. A flush valve structure according to  claim 6 , wherein the stop member includes internal threads and the internal threads of the stop member adjustably engage the external threads of the upper tubular core segment of the guide member to adjust the position of the stop member lengthwise the upper tubular core segment of the guide member independently of the buoyancy of the float assembly and independently of the upper end of the overflow tube. 
     
     
       8. A flush valve structure according to  claim 1 , wherein the float chamber is adjustable in volume by moving the closure member relative to the upper annular wall inside the outer shell independently of adjustment of the overflow tube and said stop element. 
     
     
       9. A toilet tank installation comprising:
 a toilet tank having an interior space bounded by a floor formed with an outlet hole, 
 a water supply valve positioned inside the tank and connected to a water source, and 
 a flush valve structure comprising a valve base installed in the outlet hole formed in the floor of the toilet tank, the valve base defining a water outflow passageway having an upper end and a lower end and including a first valve member at the upper end of the water outflow passage; a float assembly that is vertically movable relative to the valve base between a sealing position in which a second valve member at a lower end of the float assembly engages the first valve member in sealing relationship and a flushing position in which the second valve member is spaced upwardly from the first valve member, the float assembly defining a passageway extending upwardly therethrough, wherein the float assembly comprises:
 an outer shell that:
 is open downwards to define an opening, 
 includes an upper annular wall opposite the opening, 
 has a lower edge at which the shell is provided with said second valve member, and 
 
 a closure member within the outer shell and cooperating with the outer shell to define a float chamber, and 
 an adjustment mechanism disposed within the outer shell and configured to selectively adjust the position of the closure member relative to the upper annular wall to selectively adjust the volume of the float chamber; and 
 
 an overflow tube extending upward through the passageway defined by the float assembly, wherein the overflow tube extends upward from a lower end in fluid communication with the water outflow passageway of the valve base to an upper end in fluid communication with the interior space of the toilet tank and is adjustable in position relative to the float assembly independently of adjustment of the closure member relative to the outer shell; and a guide member that extends upward from the valve base through the overflow tube for guiding movement of the float assembly relative to the valve base; and wherein the guide member includes a stop element at a location above the float assembly for limiting upward travel of the float assembly from its sealing position, and the stop element is adjustably positioned relative to the valve base whereby a distance of said upward travel is selectively adjustable; and wherein the guide member defines a fluid passageway delivering water originating from the water supply valve to the valve base; 
 wherein the guide member comprises:
 a lower tubular core segment with outwardly projecting ribs; and 
 an upper tubular core segment engaged with the lower tubular core segment and extends upwards. 
 
 
     
     
       10. A toilet tank flush valve structure, for use with a toilet tank that is provided with a water supply valve and has an interior space bounded by a floor formed with an outlet hole, the flush valve structure comprising:
 a valve base for installation in the outlet hole formed in the floor of the toilet tank, the valve base defining a water outflow passageway having an upper end and a lower end and including a first valve member at the upper end of the water outflow passage, 
 a float assembly that is movable relative to the valve base between a sealing position in which a second valve member at a lower end of the float assembly engages the first valve member in sealing relationship and a flushing position in which the second valve member is spaced upwardly from the first valve member, the float assembly defining a passageway extending upwardly therethrough and comprising:
 an outer shell that:
 is open downwards to define an opening, 
 includes an upper annular wall opposite the opening, and 
 has a lower edge at which the shell is provided with said second valve member, 
 
 a closure member within the outer shell and cooperating with the outer shell to define a float chamber, and 
 an adjustment mechanism disposed within the outer shell and configured to selectively adjust the position of the closure member relative to the upper annular wall to selectively adjust the volume of the float chamber, 
 
 an overflow tube extending upward through the passageway defined by the float assembly, wherein the overflow tube is adjustably attached to the float assembly and extends upward from a lower end in fluid communication with the water outflow passageway of the valve base to an upper end in fluid communication with the interior space of the toilet tank, and 
 a guide member that extends upward from the valve base through the overflow tube for guiding movement of the float assembly relative to the valve base, the guide member comprising a lower portion that extends upward from the valve base through the overflow tube, an upper portion that is releasably attached to the lower portion at an upper end thereof and extends upward from the upper end of the lower portion, and a stop element mounted on the upper portion at a location above the float assembly for limiting upward travel of the float assembly from its sealing position, the stop element being adjustably positioned relative to the valve base whereby a distance of said upward travel is selectively adjustable. 
 
     
     
       11. A toilet tank flush valve structure according to  claim 10 , wherein the lower portion of the guide member comprises a tubular core and ribs projecting outward from the core and the upper portion is tubular, whereby the guide defines an internal passageway extending longitudinally of the guide member from an inlet at an upper end region of the guide member, for connection to the water supply valve, to an outlet at a lower end region of the guide member in fluid communication with the water outflow passageway of the valve base. 
     
     
       12. A flush valve structure according to  claim 10 , wherein the upper annular wall comprises a downward extension tube and the overflow tube extends within said downward extension tube. 
     
     
       13. A flush valve structure according to  claim 12 , wherein the extension tube has an upper portion of internal diameter slightly greater than the external diameter of the overflow tube, to provide a snug sliding fit of the overflow tube within said upper portion of the extension tube, and a lower portion of reduced internal diameter relative to the upper portion for cooperating with the guide member for guiding movement of the float assembly. 
     
     
       14. A flush valve structure according to  claim 10 , wherein the valve base includes a flange for positioning within the tank above the floor of the toilet tank, a water outflow tube that extends downward from the flange to enter the outlet hole formed in the floor of the toilet tank, and an extension that flares upward from the flange, and the first valve member is attached at an upper end of the extension in a position where it may be replaced inside the tank without removing the valve base. 
     
     
       15. A flush valve structure according to  claim 14 , wherein the extension is horizontally skewed, whereby the upper end of the extension is horizontally offset from a lower end thereof. 
     
     
       16. A flush valve structure according to  claim 15 , wherein the valve base has an internally threaded hole at one side of the water outflow passageway within the valve base sidewall and within the interior of the valve base and the guide member is externally threaded at its lower end and is in threaded engagement with the valve base. 
     
     
       17. A flush valve structure according to  claim 15 , wherein the guide member has a lower end at which it is threadedly attached to the valve base. 
     
     
       18. A flush valve structure according to  claim 10 , wherein the guide member comprises a lower portion located at least partially below an upper end of the overflow tube and comprises internal threads at the upper end of the overflow tube, and an upper portion having external threads releasably attached to the lower portion at an upper end thereof and extends upward from the lower portion, and the stop element is attached to the upper portion at a location above the float assembly. 
     
     
       19. A flush valve structure according to  claim 18 , wherein the upper portion of the guide member is adjustable in position lengthwise relative to the lower portion of the guide member. 
     
     
       20. A flush valve structure according to  claim 18 , wherein the stop member is internally threaded and is adjustable in position lengthwise of the guide member independently of the buoyancy of the float assembly and independently of the upper end of the overflow tube. 
     
     
       21. A flush valve structure according to  claim 10 , wherein the closure member is adjustable in position relative to the upper annular wall within the outer shell to adjust the volume of the float chamber independently of adjustment of the overflow tube and said stop element. 
     
     
       22. A toilet tank installation comprising:
 a toilet tank having an interior space bounded by a floor formed with an outlet hole, 
 a water supply valve positioned inside the tank and connected to a water source, and 
 a flush valve structure comprising a valve base for installation in the outlet hole formed in the floor of the toilet tank, the valve base defining a water outflow passageway having an upper end and a lower end and including a first valve member at the upper end of the water outflow passage; a float assembly that is movable relative to the valve base between a sealing position in which a second valve member at a lower end of the float assembly engages the first valve member in sealing relationship and a flushing position in which the second valve member is spaced upwardly from the first valve member, the float assembly comprising:
 an outer shell that:
 is open downwards to define an opening, 
 includes an upper annular wall opposite the opening, and 
 has a lower edge at which the shell is provided with said second valve member, 
 defines a passageway extending upwardly therethrough; 
 
 a closure member within the outer shell and cooperating with the outer shell to define a float chamber, and 
 an adjustment mechanism disposed within the outer shell and configured to selectively adjust the position of the closure member relative to the upper annular wall to selectively adjust the volume of the float chamber, 
 an overflow tube extending upward through the passageway defined by the float assembly, wherein the overflow tube is adjustably attached to the float assembly and extends upward from a lower end in fluid communication with the water outflow passageway of the valve base to an upper end in fluid communication with the interior space of the toilet tank; and a guide member that extends upward from the valve base through the overflow tube for guiding movement of the float assembly relative to the valve base, the guide member comprising a lower tubular core segment with outwardly extending ribs that extends upward from the valve base through the overflow tube, an upper engaged tubular core segment that is releasably attached to the lower tubular core segment at an upper end thereof and extends upward from the upper end of the lower portion, and a stop element mounted on the upper portion at a location above the float assembly for limiting upward travel of the float assembly from its sealing position, the stop element being adjustably positioned relative to the valve base whereby extension of the stop element is selectively adjustable. 
 
 
     
     
       23. A toilet tank installation according to  claim 22 , wherein the guide defines an internal passageway extending longitudinally of the guide member from an inlet at an upper end region of the guide member, connected to the water supply valve, to an outlet at a lower end region of the guide member in fluid communication with the water outflow passageway of the valve base. 
     
     
       24. A combination of flush valve components for use with a toilet tank having interior space, a water supply valve, a floor, and a valve base, the floor defining an outlet hole, the valve base extending from the outlet hole to define a water outflow passageway having an upper end and a lower end and including a flange for positioning the valve base within the outlet hole, the combination of flush valve components comprising:
 a first valve member component configured to removably attach to the upper end of the valve base; 
 a float valve assembly component having an adjustable buoyancy configured to overcome the head pressure of water above it and float upwards once a flush has been initiated and defining a passageway extending upwardly therethrough, the float valve assembly component comprising:
 an outer shell that:
 is open downwards to define an opening, 
 includes an upper annular wall opposite the opening, and 
 has a lower end; 
 
 a closure member within the outer shell and cooperating with the outer shell to define a float chamber; and 
 an adjustment mechanism disposed within the outer shell and configured to selectively adjust the position of the closure member relative to the upper annular wall to selectively adjust the volume of the float chamber, 
 
 a second valve member component at the lower end of the float valve assembly component; 
 an overflow tube component extending upward through the passageway defined by the float valve assembly component, wherein the overflow tube component extends upward from a lower end in fluid communication with the water outflow passage of the valve base to an upper end in fluid communication with the interior space of the toilet tank and is adjustable in position relative to the float valve assembly component independently of adjustment of the closure member relative to the outer shell, and 
 a guide member component that extends upward from the valve base through the overflow tube for guiding movement of the float valve assembly component relative to the valve base, and 
 wherein the guide member component includes a stop element at a location above the float valve assembly component for limiting upward travel of the float valve assembly component from its sealing position, and the stop element is adjustably positioned relative to the valve base whereby a distance of said upward travel is selectively adjustable, and wherein the guide member component defines a fluid passageway extending from above the float assembly to the valve base; 
 wherein the float valve assembly component is movable relative to the first valve member between a sealing position in which the second valve engages the first valve member component in sealing relationship and a flushing position in which the second valve member component is spaced upwardly from the first valve member component; 
 wherein the guide member component defines a fluid passageway delivering water originating from the water supply valve to the valve base; 
 wherein the guide member component comprises:
 a lower tubular core segment with outwardly projecting ribs; and 
 an upper tubular core segment engaged with the lower tubular core segment and extends upwards. 
 
 
     
     
       25. A flush valve structure according to  claim 1 , wherein the valve base includes a flange for positioning within the tank above the floor of the toilet tank, a water outflow tube that extends downward from the flange to enter the outlet hole formed in the floor of the toilet tank, and an extension that extends and is skewed upwardly from the flange, and the first valve member is attached at an upper end of the extension. 
     
     
       26. A flush valve structure according to  claim 1 , wherein:
 the lower tubular core segment is internally threaded proximate the upper end of the overflow tube; 
 the upper tubular core segment is externally threaded and releasably engaged with the internal threads of the lower tubular core segment at an upper end of the lower tubular core segment; and 
 the stop element is threadingly attached to a medial portion of the externally threaded upper tubular core segment; 
 wherein the stop element is threadingly adjustable lengthwise relative to the upper tubular core segment. 
 
     
     
       27. A flush valve structure according to  claim 1 , wherein:
 the upper tubular core segment is slidably adjustable with the lower tubular core segment with outwardly projecting ribs and is externally threaded at its upper end; and 
 the stop element is threadingly attached to said upper end of the upper tubular core segment; 
 wherein sliding adjustment of the upper tubular core segment relative to the lower tubular core segment thereby adjusts the vertical position of the stop element, and further comprising a releasable lock mechanism selectively locking the position of the upper tubular core segment relative to the lower tubular core segment. 
 
     
     
       28. The flush valve structure of according to  claim 6 , further comprising a releasable lock mechanism selectively locking the position of the upper tubular core segment relative to the lower tubular core segment. 
     
     
       29. The flush valve structure of according to  claim 26 , further comprising a releasable lock mechanism selectively locking the position of the upper tubular core segment relative to the lower tubular core segment. 
     
     
       30. The flush valve structure according to  claim 26 , wherein the stop element defines a first stop element and further comprising an internally threaded stop element threadingly engaged with the upper tubular core segment in a position tightly abutting the first stop element. 
     
     
       31. The flush valve structure according to  claim 4 , further comprising:
 a first valve member water agitator defining a collar fitted about the valve base wherein standard push-on T-fitting water jets secured within the collar may be adjustably rotated upwards and inwards towards the first valve member; 
 a toilet tank float controlled fill valve configured to discharge water into the toilet tank when open; 
 a secondary outlet that is connected by a T-coupling and flexible hose coupling at the top of the upper tubular core segment of the guide member; 
 wherein the T-coupling further couples the secondary outlet of the toilet tank float controlled fill valve to the first valve water agitator defining the collar. 
 
     
     
       32. The flush valve structure according to  claim 31 , wherein the first valve member water agitator is disposed between the flange and the first valve member. 
     
     
       33. The flush valve structure according to  claim 1 , wherein the valve base includes a flange having a lip, the flange extending within the toilet tank outward of the outlet hole in the floor of the toilet tank, and further comprising a sealing member under tension when in use and positioned between the lip of the flange and the floor. 
     
     
       34. The flush valve structure according to  claim 33 , wherein the sealing member is accessible at an outer periphery of the flange, whereby the sealing member is replaceable without removing the valve base from the floor of the toilet tank. 
     
     
       35. The flush valve structure according to  claim 15 , wherein the flange has a lip and further comprising a sealing member positioned between the lip and the floor, the sealing member being under tension when in use. 
     
     
       36. The flush valve structure according to  claim 35 , wherein the sealing member is accessible at an outer periphery of the flange, whereby the sealing member is replaceable without removing the valve base from the floor of the toilet tank. 
     
     
       37. The toilet tank flush valve structure according to  claim 10 , wherein the closure member is selectively positioned and fixed at a particular position relative to the upper inner annular wall to selectively establish and fix the volume of the float chamber.